Bracket System for Lighting Assemblies

This application claims priority under 35 U.S.C. 119 from U.S. Provisional Application No. 63/654,745, filed May 31, 2024, titled “Bracket System For Lighting Assemblies,” which is incorporated herein by reference in its entirety.

In many applications, it may be useful to secure lighting assemblies, electrical boxes and other components to ceiling structures or other members. Conventionally, mounting brackets are used to secure various support structures, which may support a lighting assembly, an electrical box or component, to ceiling members.

Some embodiments of the invention provide a method for securing a lighting assembly to a ceiling structure. The method can include providing a bracket system that includes a support structure. The support structure can include a support section that supports a lighting assembly of the lighting system, and an attachment end connected to the support section. The method can include securing the attachment end to a mounting bracket of the bracket system. The mounting bracket can include a support channel defined between first and second support members of the mounting bracket. The method can include attaching the mounting bracket to a ceiling member of the ceiling structure by sliding the mounting bracket onto the ceiling member to an installed configuration. In the installed configuration, a base of the ceiling member can support a ceiling covering against gravity. A stem of the ceiling member can extend upwardly from the base and can be received into the support channel. The mounting bracket can be seated on a top surface of the ceiling covering to support the support structure relative to the ceiling member.

Some embodiments of the invention provide a bracket system for securing a lighting assembly to a ceiling structure. The lighting system can include a support structure that includes a support section that supports a lighting assembly, and an attachment end connected to the support section. The lighting system can also include a mounting bracket that includes a support channel defined between first and second support members of the mounting bracket and can be configured to slidably engage a ceiling member of the ceiling structure. The attachment end of the support structure can be secured to the mounting bracket. The mounting bracket can be attached to the ceiling member in an installed configuration. In the installed configuration, a base of the ceiling member can support a ceiling covering against gravity. A stem of the ceiling member that extends upwardly from the base can be received into the support channel. The mounting bracket can be seated on a top surface of the ceiling covering to support the support structure relative to the ceiling member.

Some embodiments of the invention provide a method for installing a lighting system. The method can include securing a support structure to a mounting bracket of a bracket system. The mounting bracket can include a support channel defined between first and second support members. The method can include, with the support structure secured to the mounting bracket, attaching the mounting bracket to a ceiling member. This can be done by inserting a stem of the ceiling member into the support channel, and after inserting the stem into the support channel, moving the mounting bracket downward toward a base of the ceiling member that supports a ceiling covering, until the mounting bracket can be seated on the ceiling covering to support the support structure relative to the ceiling member.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.

As noted above, in some contexts, it may be useful to secure or support components relative to certain structures. For example, electrical components, including lighting assemblies, may need to be mounted in a ceiling structure. Conventional mounting assemblies commonly use fasteners and mounting brackets to secure a support structure to areas of a ceiling structure. Using fasteners to secure a mounting bracket to a ceiling structure, however, can be undesirable because it can make installation difficult and less modifiable. Some conventional configurations have attempted to alleviate this problem by providing mounting brackets that can be secured to ceiling structures without fasteners, but these configurations often result in low retention strength. Securing conventional mounting brackets to support structures with fasteners is commonly a difficult, tedious task because stabilizing and supporting the structures during assembly is challenging due to their geometries. Additionally, securing brackets to specific portions of a ceiling structure (e.g., a bulb of a T-grid ceiling structure, discussed below) utilizing a fastener may be prohibited, limiting the use cases of conventional mounting brackets.

In some contexts, it may be useful to secure or support lighting assemblies specifically relative to T-grid ceiling structures, in which ceiling members typically include a base and a vertical stem extending upwardly from the base to a bulb. In different installations, the total length of the vertical stem may vary substantially. Accordingly, although some conventional brackets may securely engage a T-grid structure of certain stem lengths, these brackets may be less secure for other stem lengths. Therefore, contractors may be required to stock many different sizes of brackets to accommodate different sizes of T-grid stems, or may be forced to accept less secure attachment to some ceiling structures.

In the context of mounting lighting assemblies to ceiling structures, it may be important to properly align the lighting assemblies relative to a ceiling cover of the ceiling structure (e.g., ceiling tiles, hard lid covers, or other known ceiling covers). Unlike other components that may offer some degree of adjustability post-installation, lighting assemblies typically require precise positioning and alignment at the time of installation to meet both aesthetic and functional requirements. Specifically, certain building codes may require a front face of the lighting assembly to be installed flush with a downward facing surface of the ceiling cover (relative to gravity). As conventional lighting assemblies are generally not height-adjustable, the conventional lighting assemblies may extend a fixed distance (e.g., non-adjustable distance) from a bracket system. The fixed distance may correspond to common ceiling covering thicknesses (e.g., ½″, ⅝″, 1″, or any other common ceiling covering thickness), so that the front face of the lighting assemblies extending through ceilings cover are flush with the downward facing surface of the ceiling covers. However, conventional brackets may often be unsuitable to properly align lighting assemblies relative to the ceiling cover, especially in the context of T-grid structures that may have stems of varied lengths.

Embodiments of the invention can help alleviate these issues, and others. For example, embodiments of the invention may provide a mounting bracket for securing a support assembly, and in particular for securing a lighting assembly to ceiling structures. The mounting bracket can easily secure the support assembly to the support structures to support lighting assemblies or other devices relative to the building structures. Embodiments of the invention may also provide a mounting bracket that can be secured to a T-grid ceiling structure without additional hardware, such as screws or other loose fasteners, while providing enhanced retention over a variety of lengths of T-grid stems and thicknesses of ceiling covers.

Embodiments of the invention can include the mounting bracket that is mountable to a variety of different T-grid ceiling structures. For example, a support channel of the mounting bracket that receives a stem and bulb of a T-grid ceiling member can retain T-grid ceiling members having a plurality of different heights and configurations. In this regard, some examples may usefully be configured—and may correspondingly be installed-so that a mounting bracket that secures a lighting system to a T-grid ceiling member is seated on the material of the ceiling covering, rather than on the T-grid ceiling members itself. For example, as detailed in examples below, some brackets can be seated on a top surface of a ceiling tile that supported by the relevant T-grid ceiling member, while remaining spaced vertically apart from a base of the relevant T-grid ceiling member. Thus, for example, the mounting bracket can secure a lighting system (or other assembly) against being removed vertically from the T-grid ceiling member while also accommodating a wide range of T-grid stem heights due to the engagement of the bracket with the ceiling covering for support relative to gravity (e.g., rather than engagement with a support base the T-grid ceiling member).

In particular, some embodiments of the disclosed mounting bracket (and related support systems) can include a contact member that extends from support members that define a support channel. The contact member can be aligned to engage a ceiling covering of the T-grid ceiling structure in an installed configuration to support the mounting bracket (e.g., and an associated lighting system) when the support channel receives a stem of a T-grid (or other) ceiling member. Specifically, the contact member can be seated on a top surface of the ceiling covering to support the support assembly relative to the T-grid ceiling member and the ceiling covering. Seating the contact member on the top surface of the ceiling covering may advantageously secure the lighting assembly relative to the ceiling covering such that the front face of the lighting assemblies extends through the ceiling covering to be flush with the downward facing surface of the ceiling covering, regardless of the actual length of a T-grid stem in the relevant ceiling system.

Embodiments of the invention are presented below in the context of support structures or brackets intended to secure lighting assemblies to ceiling structures, including T-grid ceiling structures. Although these configurations can be particularly useful in some contexts, including due to the particular requirements for mounting lighting assemblies to ceiling structures, other configurations are possible. For example, the principles disclosed herein can be used with support structures intended to secure any variety of mountable components, including electrical boxes, vents, audio devices, fire alarms, and so on. Similarly, although some particular examples of T-grid structures are illustrated in the FIGS., some embodiments can be used with other T-grid structures (e.g., with taller or shorter stems, or differently configured bulbs) or otherwise.

As noted above, embodiments of the present invention generally provide a bracket system for mounting and adjustably securing a light assembly or other object to a ceiling structure.illustrates an example support assemblyconfigured to support various equipmentbetween a first and second building structure,. For example, as illustrated, the support assemblycan be part of a lighting system (e.g., a multi-piece lighting assembly) and the building structures,can be tees of a T-grid ceiling or studs of a hard lid ceiling assembly, although other configurations are possible (e.g., with other supported equipment, other installation contexts, etc.).

In particular, the support assemblycan include a centerplateconfigured to receive and retain the equipment. Additionally, the support assemblycan include a support bracketthat can be configured to support the centerplaterelative to the building structures,. In some examples, the support bracketcan be a telescopically adjustable bracket having a first bracket memberand a second bracket member. For example, the first bracket memberand the second bracket membercan be secured to the centerplateand adjustable relative to the centerplateto adjust an extension length of the support bracket, allowing the support assemblyto be secured between first and second building structures,(e.g., T-grid ceiling members, as shown) that are spaced apart by various distances.

In the embodiment illustrated, the support assemblyis a telescoping ceiling bracket, however alternative structures or brackets may be used. For example, a support assembly could be any structure that includes one or more planar end portions that are configured to be received by a channel. Further, for example, a support assembly could be any structure having one or more flanged portions that can be inserted into a channel or slot. Further, a support portion of a support assembly, for example, can include any known type of configuration that is capable of supporting one or more lighting assemblies or other components. Therefore, mounting brackets according to embodiments of the present disclosure as described further below can be used to support or secure a variety of structures, including structures not expressly illustrated herein.

In some examples, the support assemblycan include mounting brackets to secure the support bracketrelative to the building structures,. For example, in the embodiment illustrated in, a pair of mounting bracketscan secure the bracketto the building structures,. Although the support assemblyaccording to the present embodiment is illustrated with two of the mounting brackets, any number of mounting brackets may be used in other installations. For example, in some instances, the bracket system may include one, three, or four mounting brackets. Further, in some embodiments, sets of substantially identical mounting brackets can be used. However, in other embodiments, the mounting brackets may define one or more different characteristics, for example, one of the mounting brackets may be longer than another.

As will be described in greater detail herein, the support assemblyis configured so that it may be easily assembled prior to installation into a ceiling structure (e.g., onto the building structures,). Specifically, the support assembly can be assembled on a work bench or other surface before being attached to the building structures,. As also described further below, the mounting bracketsmay be attached to the building structures,without additional hardware, such as fasteners. Thus, the mounting bracketscan be removably secured to the building structures,in some cases. Further, the support assemblyis generally provided to support the equipmentat a particular height relative to the building structures,and a ceiling covering extending between the building structures,.

In different installations, mounting brackets according to embodiments of the invention can be readily secured to a variety of ceiling structures. For example,illustrate aspects of a particular configuration of the building structures,that may be used with the mounting bracketaccording to embodiments of the present disclosure. The illustrated mounting bracketis provided for example purposes only, and other configurations are possible. Referring particularly to, in the embodiment illustrated, each of the building structures,includes a flat baseand a stem. The stemcan extend from the flat baseto a widened top(e.g., a bulb).

Specifically, the stemcan extend upward (relative to gravity) from the base. In some examples, the stemcan extend substantially perpendicularly from the flat base. However, in other examples, the stemmay extend obliquely from the flat base. In some examples, a height of the building structures,, measured between the baseand a distal end of the widened top(e.g., opposite the base), can vary. As described further below, the mounting bracketmay be configured to accommodate the building structures,of varying heights and configurations.

Although the building structures,according to the present embodiment are T-grid ceiling members that include the stemwith the widened top, a variety of other configurations are possible. For example, the support assemblyaccording to the present invention may be configured to mount to any variety of a ceiling member or non-ceiling members. However, some embodiments may be particularly well suited for use with T-grid ceiling members, including due to the ability to accommodate a wide variety of heights of the vertical stems thereof.

Generally, support brackets according to the invention can include a variety of support rail configurations with ends that allow attachment to a mounting bracket. Returning to, the support bracketaccording to the present embodiment is a ceiling bracket that includes a plurality of attachment ends(e.g., two attachment ends). In some examples, the support bracketcan include a plurality of support rails(e.g., two support rails). Furthermore, the attachment endsof the support bracketcan connect the plurality of support rails. For example, the attachment endscan connect the support railsat opposite ends of attachment ends. Furthermore, the plurality of support railscan extend substantially parallel to each other between the attachment ends. The support railscan define a support section that is provided to support components, such as the centerplateand the equipment. Further, in the embodiment illustrated, the plurality of support railscan be telescoping (i.e., their lengths may be selectively adjusted), allowing the support assemblyto be telescopically adjusted; however alternative configurations are possible. In some examples, the attachment endscan be symmetrical about the support rails, and, accordingly, the attachment endscan share substantially identical aspects.

As best shown in, each of the attachment ends(see also) is a thin, elongate, planar section that is configured to be received by and secured to the mounting bracket. The attachment endillustrated in, further includes a holethat is configured to receive a fastener, such as a screw or a bolt, which will be described in greater detail below. Moreover, a shoulderis disposed at a junction between each of the attachment endsand the support section, e.g., the support rails. In some embodiments, the shouldermay be used to secure the support backetto the mounting bracket, an example of which will be described below. However, other configurations for support brackets, including their ends and support sections, are possible. For example, in some embodiments, ends of a support bracket may be non-planar or may not include a shoulder as shown in.

illustrate an example configuration of the mounting bracketfor use in the support assemblyofaccording to an embodiment of the invention. Referring to, the mounting bracketis formed as a stamping from a single blank, which is bent to form a three-dimensional bracket body, although a variety of other approaches are possible. Accordingly, the mounting bracketis integrally formed as a single unitary component. In some embodiments, a mounting bracket can be formed from spring steel. In some cases, spring steel may be particularly suitable, due to its high degree of elasticity and significant load strength. Furthermore, in some embodiments, a mounting bracket may be heat treated. For example, a mounting bracket can be formed from spring steel that is through hardened to enhance a hardness and tensile strength of the mounting bracket material. Other heat treatments may alternatively be used.

With continued reference to, the mounting brackethas a bracket bodythat includes a first support memberand a second support member. As described further below, the second support membercan extend from the first support memberto define a channel for receiving the building structures,. In some examples, the second support memberincludes a first arm, a second arm, and a third arm. The first and second arms,can extend from the first support member. Furthermore, a first contact memberand a second contact membercan extend from the second support member. For example, the first contact membercan extend from the first armand the second armand the second contact membercan extend from the third arm.

Again, each of the first support member, the second support member, the first arm, the second arm, the third arm, the first contact member, and the second contact membercan be integrally formed as part of a single component, and are a result of stamping and bending a blank material, e.g., spring steel. In different embodiments, different arrangements and geometries are possible for the components noted above.

Still referring to, the first support memberis planar, extending substantially along a single plane defined by the first support member. In the embodiment illustrated, the first support memberincludes a hole(e.g., for use as a locating feature during stamping operations), but other configurations are possible. For example, the holemay receive a fastener (not shown) to secure the mounting bracketto the building structures,.

In some examples, the second support memberextends from a first edgeand a second edgeof the first support member. For example, as best seen in, the first armextends from the first edgeof the first support member. The first edgecan define a bend such that at least a portion of the first armextends along and adjacent to the first support member. The first edgeis generally a bend line that is formed by bending the first armrelative to the first support member. Accordingly, the first edgeincludes a radius of curvature, which may be between about 1.3 mm and 3.5 mm in some embodiments, but other configurations are possible.

Furthermore, as best seen in, the second armsimilarly extends from the second edgeof the first support member. The second edgecan define a bend such that at least a portion of the second armextends along and adjacent the first support member. Thus, the second edgeis generally a bend line that is formed by bending the second armrelative to the first support member. The second edgemay have a radius of curvature between about 1.3 mm and 3.5 mm, but other configurations are possible. In some examples, the first edgeand the second edgecan be substantially collinear or coplanar.

In some examples, the second support membercan be planar. For example, the first armand the second armcan extend parallel to one another and along a common plane. However, as described further below, the second support membercan include sections that are not co-planar with the arms,.

In some examples, the second support membercan extend substantially parallel to the first support member. For example, the second support membercan extend substantially parallel to the first support memberalong a support channelformed between the first support memberand the second support member. As described further below, the support channelcan extend from a blind end(e.g., a connection between the first support memberand second support member) to free ends of the first and second support members,. In such examples, the second support membercan extend substantially parallel to the first support memberalong between the first contact memberand the blind endof a support channel. More specifically, referring to, in some embodiments, the first and second arms,may extend substantially parallel to the first support member.

However, in other embodiments, the second support membermay extend obliquely relative to the first support member. For example, the first armand the first support membermay form an oblique angle (e.g., less than 5 degrees, less than 10 degrees, less than 20 degrees, or less than 30 degrees). Furthermore, the second armand the first support membermay form an oblique angle (e.g., less than 5 degrees, less than 10 degrees, less than 20 degrees, or less than 30 degrees). Additionally, the angle between the first armand the first support memberand the angle between the second armand the first support membercan be equal.

Still referring to, a tabhaving a slotcan extend from the first support memberbetween the first and second arms,and the first and second edges,. Generally, the slotof the tabis provided to receive cables or wires to bear the weight of a support structure and any component provided thereon, thereby decreasing loads on a ceiling structure (e.g., to comply with seismic regulations). While the tabis integrally formed with the first support memberin the illustrated embodiment, tabs or elements for receiving cables or wires to bear the weight of the support structure or components may be individually fabricated and coupled to a bracket body in alternative embodiments. Further, while the tabextends from the first support memberand is bent away from the first and second arms,in the illustrated embodiment, other configurations are possible. For example, a mounting bracket may include a tab that is substantially coplanar with a first support member (i.e., extends substantially parallel to the plane of the first support member).

As described above, the contact members,can extend from the second support member. In some examples, the first contact membercan be connected to the first and second edges,of the first support memberby the first and second arms,. Therefore, via the second support member(e.g., via the first and second arms,), the first contact membercan resiliently move relative to, yet remain connected to, the first support member.

The first contact membercan extend from the first and second arms,of the second support member. More specifically, the first contact membercan be connected to the first and second arms,by bend lines (e.g., made by stamping). Thus, the bend lines can be defined at a junction between the first contact memberand the first and second arms,. In some examples, the first contact membercan extend across an openingdefined between the first and second arms,to connect the first and second arms,. In some examples, the openingmay be a stamped opening that substantially corresponds to the third arm, which will be described in greater detail below.

In the illustrated embodiment, for example, the first contact memberis planar, extending substantially along a single plane defined by the first contact member. In some examples, the first contact membercan extend substantially perpendicular (e.g., transverse) to the second support member(e.g., the first and second arms,) or the first support member. For example, the plane defined by the first contact membercan extend substantially perpendicular to the second support member. Relatedly, and as discussed further below, the first contact member(or the plan define thereby) can extend substantially perpendicular to an insertion direction of the building structures,into the support channel, or may similarly extend substantially parallel with horizontal (e.g., substantially parallel to a supporting top surface of a ceiling covering).

The third armextends from third and fourth edges,of the first contact memberin a direction opposite the first and second arms,. Generally, the third armcorresponds to the stamped openingdefined between the first and second arms,. For example, the material blank can be stamped to define an outline of the stamped opening, which also corresponds to the third arm. Accordingly, the third armcan be bent away from the first and second arms,about the first contact member, thereby creating the stamped opening.

As described above, the second support membercan be planar. Referring to, in some embodiments the third armand may be substantially parallel to and may extend along a common plane as the first and second arms,. That is, the third armand the first and second arms,may be bent away from each to form an angle of about 180 degrees. In such embodiments, the third armcan extend parallel to the first support member, and an entirety of the second support membermay extend along a common plane.

In other examples, only sections of the second support membermay be planar. For example, the second support membercan be planar between the blind endof the support channeland the first contact member(e.g., between the edges,and the first contact member). Furthermore, the third armcan extend obliquely relative to the first and second arms,. That is, the third armand the first and second arms,may be bent away from each to form the angle between about 160 degrees and about 200 degrees or between about 170 degree and about 190 degrees. In such embodiments, the third armcan extend obliquely relative to the first support member, and third armmay not extend along plane that is common to the first and second arms,. Furthermore, in such embodiments, the third armcan extend toward the first support memberto decrease a width of the support channel(as described further below).

Returning to, the third and fourth edges,are bend lines defined between the first contact memberand the third arm. In some examples, the third armcan extend substantially perpendicularly from the first contact memberlaterally between and vertically opposite the first and second arms,. However, in other examples, the third armmay extend obliquely relative to the first contact member. For example, the third armand the first contact membermay be bent away from each to form the angle between about 70 degrees and about 90 degrees or between about 80 degrees and about 90 degrees.

As described above, in the illustrated embodiment, as shown inin particular, the first contact memberextends substantially perpendicularly to the support channelfor receiving the building structures,(and substantially in parallel with a plane defined between free ends of the first and second support members,, as further discussed below). Accordingly, the first contact membercan extend substantially perpendicularly to a stem of a T-grid member (or substantially in parallel with a T-grid base) when installed (as shown in). Thus, for example, the first contact membercan provide an extended horizontal support for a support structure that is supported by the mounting bracket.

Referring again to, as described above, the second contact membercan extend from the second support member. As described further below, in an installed configuration, the second contact membercan be positioned above the first contact member, relative to gravity. Consequently, in the installed configuration, the first contact membercan be the lower member of the contact members,(e.g., and can correspondingly seat on a ceiling covering to support a larger lighting system).

As illustrated in, the second contact memberextends from a fifth edgeof the second support member, which is disposed between the third and fourth edges,and, thus, the first and second arms,. Generally, the second contact membercorresponds to a stamped openingdefined along the first contact member. The second contact memberthus can be formed by bending a portion of material stamped from the first contact memberthat results from the stamping of the stamped opening. More specifically, the second contact memberin the illustrated embodiment is defined by bending the material about the fifth edge, relative to the first contact member.

Although the second contact memberis generally elevated relative to the first contact member, it may still maintain alignment with the stamped opening. That is, the second contact membermay be at least partially aligned with a profile of the stamped opening(sec, e.g.,).

The second contact memberextends substantially along a single plane defined by the second contact memberfrom the fifth edgein a direction similar to the first contact member. In some examples, the second contact membermay be substantially parallel to the first contact member. However, in other examples, the second contact membercan extend obliquely relative to the first contact member. For example, the second contact membercan extend at an angle that is less than about 20 degrees, less than about 10 degrees, or less than about 5 degrees relative to the first contact member.

As described above, the second contact memberis generally offset from the plane of the first contact member(e.g., elevated above the first contact member, relative to gravity). The first and second contact members,can therefore be spaced apart to define a contact channelbetween the first and second contact members,.

The contact channelgenerally extends between the first contact memberand the second contact memberto allow for insertion of a component to be secured to the bracket body(e.g., the support bracketof). Additionally, in the illustrated embodiment, the second contact memberincludes a flared distal end. The flared distal endmay extend obliquely from the second contact memberin a direction that is away from the first contact member. In some cases, this configuration can further assist insertion of a component into the contact channel, by creating an enlarged entrance of the contact channel. However, other configurations are possible, including, but not limited to, configurations without an outwardly flared distal end.

Still referring to, the second contact memberis generally configured to move relative to, yet remain coupled to, the first contact member. Therefore, when (or as) a component, such as the support bracket(e.g., the attachment endas shown in) is inserted therebetween, the first and second contact members,resiliently separate to receive the support bracketinto the contact channel. Furthermore, the contact members,can resiliently clamp the inserted attachment endwithin the contact channelto secure the support bracketrelative to the mounting bracket. Thus, when the bracket(e.g., the attachment end) is inserted between the first and second contact members,, the contact members,may resiliently clamp the component therebetween, as can help to secure the component until a fastener, or other securing element, is added (and thereafter).

As described above, the second contact membercan extend from the fifth edgeto the distal endtoward the first contact member, at an oblique angle relative to the first contact member. In such examples, a width of the contact channel, measured perpendicular to the insertion direction of the support bracketinto the contact channel, may taper. For example, the contact channelcan define a maximum width proximate the fifth edge, and can decrease in width as the contact channelextends toward the distal end; however, as described above, the contact channelcan again widen proximate the distal end.